Enhanced protection and security shutter system

ABSTRACT

A shutter system for covering an opening, such as a window or door, in a building. In one embodiment, the shutter system includes a housing and a shutter. The shutter is coupled to a torque tube within the housing and includes a plurality of slats, at least one of which comprises a non-opaque polycarbonate material for transmitting light and allowing viewing through the shutter. In one embodiment the shutter system further includes at least one storm bar for reinforcing the shutter. The storm bar is mounted adjacent the shutter and extends from the top end of the shutter to the bottom end of the shutter.

FIELD

The invention relates generally to systems for covering and securing openings within buildings such as windows or doors. More particularly, embodiments of the invention include shutter systems that protect building openings during intense periods of weather and/or secure building openings at other times.

BACKGROUND

Businesses and homes include one or more doors, and often are designed with one or more windows for the benefit and pleasure of building occupants. During times of severe weather, however, doors, windows, and other openings in a building provide points of vulnerability within an otherwise sound structure. Damaging winds, flying debris, and falling objects present a threat to people within the structure because they often damage or break windows and doors, strewing glass about, and hurtling projectiles through windows, doors, or other openings in the structure.

Several solutions for addressing these concerns have various drawbacks. In preparation for severe weather, such as in the case of a potential hurricane landfall, business and home owners can be seen “boarding up” openings in their buildings with plywood, wooden planks, metal sheets and other materials. These materials provide a temporary solution and must be attached and detached from the building before and after every chance of severe weather. It can be difficult to protect upper level windows and doors in this manner, usually requiring the assistance of, for example, ladders or scaffolding. In addition, boards and sheets block valuable daylight from entering the interiors of buildings, which can be helpful when electricity is unavailable due to the storm. While not letting light in, these materials also prevent occupants from looking out of the building, leaving them unable to assess the safety of their immediate surroundings.

When not covered up for storm protection, windows and doors also present security concerns for owners and occupants alike. Unfortunately, unwanted entry, such as in the case of theft, burglary, and more dangerous crimes, is a real issue for people. Thus, security barriers that are strong and reliable are necessary. Glass windows and breakable closure doors do not meet this need.

Securing retail stores and other buildings is traditionally accomplished by using steel roll down shutters, chain link gates, sliding door panels, and other closure techniques. This kind of security creates several undesirable circumstances. For example, it is no longer possible for shopkeepers or other businesspeople to show their merchandise to the passing public. There is a desire to show their merchandise and display product models even when the shop is closed. In addition to product display, advertising opportunities and information display are also important. Naturally, shop windows, doorways, and other openings create an opportunity to achieve this advertising. Unfortunately, it is not possible to use in-store advertising systems like narrowcasting, posters or banners when security means, e.g., closed shutters, cover the displayed information. Further, the closed shutters or gates create an unfriendly atmosphere.

Various improvements in shutter systems have been done. For example, U.S. Pat. No. 5,383,315 to Birs discloses an improved shutter in which a plurality of interlocking corrugated panels are attached between a header above the opening and sill below the opening. Also, U.S. patent application Ser. No. 10/687,806 to Vincent discloses a shutter system for covering a wall opening includes a retractable and deployable barrier assembly and at least one pair of cooperating support braces.

There are also known shutter systems that provide protection against hurricanes. For example, U.S. Pat. No. 5,469,905 to McKinney et al., discloses a security and shutter of greater strength that uses blades which are longitudinally pivoted to each other. U.S. Pat. No. 5,487,243 to Hale et al., discloses a shutter system for protecting building interiors against severe weather conditions such as hurricanes. The shutter system described is stackable comprising plurality of panels, and are adapted for pressure fit within a window frame. Also, U.S. Pat. No. 5,595,233 to Gower relates to a hurricane shutter formed from double skinned panels that are strengthened by including a rod extending through the end channels.

However, there does not exist any shutter system that fulfills the desire of the shopkeepers to show their merchandise and display product models even when the shop is closed. The above mentioned needs create competing concerns/interests. From a security and weather protection standpoint, enclosed and securely shuttered building openings are desired. In order to derive the benefits of windows and doors, it is desirable to keep them open. Also, from an advertising perspective, an open configuration is desired which allows for viewing and display. It is also desirable to present information more directly to people viewing the shutter. For example, in the presence of severe weather, shopkeepers may wish to display weather related information, such as weather warnings, emergency information, or modified store hours. In other cases, it can be advantageous to present advertisements to passersby when the shop is closed due to weather related activity or otherwise. Or, managers of larger facilities, such as airports, may wish to use a shutter system with a projection system.

Thus, there is a need for a system that achieves the desired weather protection, security, viewing, and display of information, among other needs that will be appreciated in the course of this disclosure.

SUMMARY OF INVENTION

A shutter system is provided according to various embodiments for covering an opening in a wall of a building.

According to an embodiment of the invention, there is provided a shutter system wherein the shutter system comprises a housing and a shutter. The shutter includes a first side end, a second side end, a top end, a bottom end, and a plurality of panels each comprising a slat. At least one of the slats comprises a non-opaque polycarbonate material. The shutter is coupled at the top end to a torque tube within the housing. The shutter system further includes first and second side rails that define tracks for receiving the first and second side ends of the shutter. The side rails are mounted adjacent the sides of the opening. The shutter rolls up and down within the tracks defined by the first and second side rails. However, it is contemplated that any suitable mechanism may be used to roll up the shutter, including, but not limited to, the torque tube and/or one or more motors or other drive assemblies.

According to another embodiment of the invention, the shutter system further includes at least one storm bar for reinforcing the shutter. The storm bar is mounted adjacent the shutter between the first and second side rails and extends from the top end of the shutter to the bottom end of the shutter.

In accordance with yet another embodiment of the invention, the shutter system comprises a plurality of panels wherein each of the panels comprises a slat along with a top hinge member and a bottom hinge member. The top and bottom hinge members of adjacent slats connect to form hinge assemblies that reinforce the slats and strengthen the shutter against breaking. In an exemplary embodiment, the top and bottom hinge members reinforce the slats in order to provide a wider shutter with longer slats. In addition, the hinge assemblies allow the panels to roll up around the torque tube within the housing and unwind.

According to yet another embodiment of the invention, the slats may comprise a polycarbonate material to provide enough strength to the system for example to withstand high winds, flying debris, and falling objects caused by severe weather. According to some embodiments, the entire shutter system is constructed to withstand hurricane force winds.

According to yet another embodiment of the invention, in the shutter system, at least one of the slats is non-opaque, providing various amounts of light transmission and transparency. In an exemplary embodiment, the slats may comprise a polycarbonate with a transparency similar to glass and with 84-90% light transmission, although embodiments are not limited to this range. In another exemplary embodiment, the polycarbonate may be colored. For example, the polycarbonate may be tinted or may include compounds to provide only unidirectional viewing such as in a “oneway” mirror. The shutter system comprising one or more non-opaque viewing slats when mounted over a building opening provides illumination for interior rooms and allows various degrees of visibility through the shutter. In some embodiments the slats allow people outside the building to see inside the building, or conversely, people inside the building to see outside the building in order to, for example, see a shopkeeper's merchandise behind a store window or assess the outside weather conditions during severe weather.

According to yet another embodiment of the invention, the shutter system has a solid construction able to withstand the forces of severe weather and people, such as vandals and thieves. In some embodiments, for example, the shutter hinges, side rails, and other components comprise 6063-T6 aluminum alloy or other suitable material. In addition, the housing and torque tube may comprise galvanized steel, among other suitable materials.

According to yet another embodiment of the invention, the shutter system may comprise slats of a longer length and storm bars may be mounted adjacent the shutter, between the first and second side rails. The storm bars extend from the top end of the shutter to the bottom end of the shutter in order to reinforce the shutter.

In some embodiments, the shutter system may comprise storm bars on both sides of the shutter to increase the strength and integrity of the shutter system, enabling it to withstand stronger forces. For example the shutter system may comprise inside storm bars mounted adjacent an inside surface of the shutter as well as outside storm bars mounted adjacent an outside surface of the shutter. In such a construction, the inside storm bars may mirror the placement of the storm bars, being positioned directly opposite the shutter from the outside storm bars.

According to yet another embodiment of the invention, the storm bars serve to hold a wider shutter in place and prevent it from disengaging from the first and second side rails when it receives a force. The storm bars help prevent the slats and shutter from bending and does not let them slip out of the first and second side rails. Further, in cases where the shutter system covers a glass-enclosed window or door, the storm bars can help prevent the shutter from being damaged, as well as the glass panel behind the shutter. In addition, in some embodiments, the thickness of the slats is designed to inhibit flexing transverse to the slat span.

To facilitate installation, some embodiments of the invention include a shutter kit. In one embodiment, a shutter kit for covering an opening of a building comprises a housing having a torque tube, a shutter having first and second side ends and top and bottom ends. The shutter comprises a plurality of panels each having a slat comprising a non-opaque polycarbonate material. The shutter is coupled at its top end to the torque tube. The kit further includes first and second side rails that define tracks for receiving the first and second sides of the shutter and a plurality of storm bars for reinforcing the shutter. It will be appreciated that this is just one possible embodied shutter kit and that other embodiments may include additional or fewer components.

According to yet another embodiment of the invention, the shutter system may cover a surface such as a building wall as well as be used for advertising. For example, in some embodiments the shutter system may be used within an airport to cordon areas of restricted access, and/or to display information such as warnings, instructions, or advertisements

According to yet another embodiment of the invention, the storm bars in the shutter system may be permanently mount. Alternatively the storm bars may also be removably mounted to the angle brackets. Removable configuration of the storm bars is helpful in situations where it is desirable to remove the storm bars when the shutter system is unneeded. For example, after the threat of a hurricane has passed, shopkeepers may prefer to remove the storm bars from in front of a store window in order to provide an unobstructed and aesthetically appealing view to passersby.

Having described embodiments of the shutter system, in one embodiment a method of securely covering an opening in a wall of a building includes providing such a shutter system including a housing, a shutter, and a first and a second side rail. As previously described, the shutter comprises a first side end, a second side end, a top end, a bottom end, and a plurality of panels. The panels each have a slat and at least one of the slats comprises a non-opaque polycarbonate material. The method further includes mounting the housing adjacent a top of the opening and mounting the first and second side rails adjacent sides of the opening to receive the shutter as it rolls up and down. The method also includes mounting at least one storm bar adjacent the shutter between the first and second side rails and extending from the top end of the shutter to the bottom end of the shutter for reinforcement.

According to yet another embodiment of the invention, the height of the slats may be varied to provide a square roll-up feature thereby maximizing the area of the shutter taken up by the slats and minimizing the area taken up by the top and bottom hinge members. Such a construction overcomes the problem of the viewing area being interrupted by the hinge assemblies, which in many cases are manufactured from an aluminum alloy, and making the shutter system aesthetically appealing. This also provides for a shutter system that allows the customers to view into a store window.

According to yet another embodiment of the invention, the shutter system may also allow for displaying information and advertisements in windows, doors, and other openings. Some embodiments of the invention provide shutter systems employing projections panels and a projection system among other components. The shutter system generally includes a shutter with a plurality of projection panels. As in other embodiments, the projection panels also operate to securely close off an opening (e.g., a window or doorway), thus providing a secure building. Each of the projection panels comprises a slat and top and bottom hinge members similar to embodiments previously described. In some embodiments, however, the slat comprises a nontransparent.( e.g. milky white) polycarbonate material having diffusion properties capable of transferring a display image projected at one side such that it can be seen when viewing the material from the opposite side. However, it will be appreciated by those skilled in the art that other materials having similar properties may also be employed. In an exemplary embodiment, the polycarbonate allows as little as 4% light transmission with a diffusion factor of about 0.8. Thus, customers and passersby can see the display image from outside the building when it is projected from inside the building.

According to yet another embodiment of the invention, the projection system may comprise a projector coupled to a computer (PC) or any other suitable controller. For example, the projector can be attached using a VGA, DVI, HDMA cable or a UTP network cable to the PC. The PC/controller includes necessary software to implement the graphic display as desired. The projection system is configured to cooperate with the projection panels to provide an effective and usable display of information. In addition, the PC could also potentially control the display of information on multiple shutter systems in various locations. Further, images containing advertisements or any other information (e.g., time, date, weather info, travel info, stock info, sports info, advertisement through internet, stock market reports etc) can be displayed to shoppers or those passing by the store. It will be easily recognizable that a wide variety of image templates are possible according to different shutter designs. As just one example, projection panels may only comprise a specific section of the shutter, with non-opaque viewing panels occupying other sections. A corresponding image template can ensure that the image is projected only onto the section of the shutter comprising the projection panels.

According to yet another embodiment of the invention, the storm bars may be coupled together with one or more support bars. The support bars provide additional strength to the shutter system, while also allowing an easier installation of multiple storm bars. For example, the support bars may extend horizontally across the tops and bottoms of the storm bars, which allows all of the storm bars to be installed simultaneously. Alternatively the storm bar may be coupled to only one support bar.

Thus, embodiments of the ENHANCED PROTECTION AND SECURITY SHUTTER SYSTEM are disclosed. Although embodiments of the invention have been described in considerable detail, other embodiments of the invention are possible. While exemplary embodiments of this invention have been illustrated and described, one skilled in the art will appreciate that various changes, adaptations, and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims.

In accordance with yet another embodiment of the invention, the shutter system covers an opening in a wall in such as but not limited to a window or door, in a building such as a store, hotel, or house. The shutter system may also be used to cover openings in any building, however these examples are not meant to be limiting. For example, the shutter system may cover an interior opening within a building, or be used to partition a building into separate spaces.

The following detailed description should be read with reference to the drawings, in which like elements in different drawings are numbered identically. It will be understood that embodiments shown in the drawings and described herein are merely for illustrative purposes and are not intended to limit the invention to any embodiment. On the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the scope of the invention as defined by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings various possible exemplary embodiments of the invention are shown. It is understood that these embodiments are simply certain examples showing how the invention could be utilized. It is also understood that several other variations are possible without departing from the scope and spirit of the invention.

FIG. 1 is a front elevation view of a shutter system according to an embodiment of the invention.

FIG. 2 is a front elevation view of a shutter system according to an embodiment of the invention.

FIG. 3 is a top cross-sectional view of a storm bar according to an embodiment of the invention.

FIG. 4 is a side cross-sectional view of a shutter system mounted according to an embodiment of the invention.

FIG. 5 is a top cross-sectional view of a fixed fastening mechanism for mounting a storm bar according to an embodiment of the invention.

FIG. 6 is a top cross-sectional view of a removable fastening mechanism for mounting a storm bar according to an embodiment of the invention.

FIG. 7 a illustrates a shutter arrangement according to an embodiment of the invention.

FIG. 7 b illustrates a shutter arrangement according to an embodiment of the invention.

FIG. 7 c illustrates a shutter arrangement according to an embodiment of the invention.

FIG. 7 d illustrates a shutter arrangement according to an embodiment of the invention.

FIG. 8 is a partial side cross-sectional view of a shutter system including a square roll-up design according to an embodiment of the invention.

FIG. 9 is a front elevation view of a shutter system including a square roll-up design according to an embodiment of the invention.

FIG. 10 illustrates a shutter system combined with a projection system according to an embodiment of the invention.

FIG. 11 illustrates a shutter system combined with a projection system according to an embodiment of the invention.

FIG. 12 illustrates multiple shutter and projection systems according to an embodiment of the invention.

FIG. 13 is a side cross-sectional view of a top hinge member according to an embodiment of the invention.

FIG. 14 is a side cross-sectional view of a bottom hinge member according to an embodiment of the invention.

FIG. 15 is a side cross-sectional view of a slat according to an embodiment of the invention.

FIG. 16 is a top cross-sectional view of a storm bar according to an embodiment of the invention.

FIG. 17 is a top cross-sectional view of a storm bar according to an embodiment of the invention.

FIG. 18 is a top cross-sectional view of a storm bar according to an embodiment of the invention.

FIG. 19 illustrates a storm bar configuration according to an embodiment of the invention.

FIG. 20 illustrates a storm bar configuration according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description should be read with reference to the drawings, in which like elements in different drawings are numbered identically. It will be understood that embodiments shown in the drawings and described herein are merely for illustrative purposes and are not intended to limit the invention to any embodiment. On the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the scope of the invention as defined by the appended claims.

FIG. 1 is a front elevation view of a shutter system 10 according to one embodiment of the invention. The shutter system 10 covers an opening (not shown) in a wall 12, such as a window or door, in a building such as a store, hotel, or house, for example. The shutter system 10 may be used to cover openings in any building, however these examples are not meant to be limiting. In some exemplary embodiments, the shutter system 10 may cover an interior opening within a building, or be used to partition a building into separate spaces. Generally, the shutter system 10 includes first and second side rails 14, 16 respectively mounted to the wall 12 adjacent first and second sides of the opening. A housing 18 is mounted abutting the top of the opening and includes a torque tube (not shown). A shutter 20 includes a top end 19, a bottom end 21, and first and second side ends 23, 25 respectively. The top end 19 of the shutter is mounted to the torque tube within the housing 18. The shutter 20 rolls up and down within tracks defined by the first and second side rails 14, 16. It is contemplated that a variety of mechanisms can be used to roll up the shutter, including, but not limited to, the torque tube and/or one or more motors or other drive assemblies.

The shutter 20 comprises a plurality of panels, which each comprise a slat 22, along with a top hinge member and a bottom hinge member (not shown) as will be described in detail hereafter. The top and bottom hinge members of adjacent slats connect to form hinge assemblies that reinforce the slats 22 and strengthen the shutter 20 against breaking. For example, in one embodiment, the top and bottom hinge members reinforce the slats 22 in order to provide a wider shutter with longer slats 22. In addition, the hinge assemblies allow the panels to roll up around the torque tube within the housing and unwind as will be shown in greater detail in FIG. 8.

In some embodiments, the slats 22 comprise a polycarbonate material that is strong enough to withstand high winds, flying debris, and falling objects caused by severe weather for example. For example, in one embodiment the polycarbonate material is Lexan polycarbonate, type 9030 as manufactured by SABIC Innovative Plastics (formerly General Electric Plastics), and is able to withstand hurricane force winds (e.g., 74 m.p.h. or greater) and projectiles. According to some embodiments, the entire shutter system is constructed to withstand hurricane force winds. For example, in some embodiments the shutter system is constructed in compliance with the High Velocity Hurricane Zone standards published in the 2004 edition of the Florida Building Code.

Advantageously, at least one of the slats 22 is non-opaque, providing various amounts of light transmission and transparency according to some embodiments of the invention. For example, in one embodiment, the slats 22 comprise a polycarbonate with a transparency similar to glass and with 84-90% light transmission, although embodiments are not limited to this range. In another embodiment, the polycarbonate may be colored. For example, the polycarbonate may be tinted or may include compounds to provide only unidirectional viewing such as in a “oneway” mirror. By including one or more non-opaque, viewing slats, the shutter 20 mounted over a building opening provides illumination for interior rooms and allows various degrees of visibility through the shutter 20. In some embodiments the slats allow people outside the building to see inside the building, or conversely, people inside the building to see outside the building in order to, for example, see a shopkeeper's merchandise behind a store window or assess the outside weather conditions during severe weather.

The shutter system has a solid construction able to withstand the forces of severe weather and people, such as vandals and thieves. In some embodiments, for example, the shutter hinges, side rails, and other components comprise 6063-T6 aluminum alloy or other suitable material. In addition, the housing 18 and torque tube may comprise galvanized steel, among other suitable materials. To provide sufficient protection against projectiles, the slats 22 are at least 6 millimeters thick in some embodiments.

FIG. 2 is a front elevation view of a shutter system 30 according to another embodiment of the invention. The shutter system 30 resembles the shutter system 10 of FIG. 1 in many respects, but includes slats 22 of a longer length and storm bars 32 mounted adjacent the shutter, between the first and second side rails 14, 16 as will be described in detail hereafter. The storm bars 32 extend from the top end of the shutter to the bottom end of the shutter in order to reinforce the shutter. As shown in FIG. 2, the storm bars 32 are secured by fastening a top end 31 of each storm bar 32 to a header 34 and a bottom end 33 of each storm bar 32 to a lower bracket, base, or slab (not shown), as will be described in greater detail hereinafter.

Although not shown in this view, in some embodiments the shutter system 30 includes inside storm bars mounted adjacent an inside surface of the shutter 20 as well as outside storm bars mounted adjacent an outside surface of the shutter 20. For example, the inside storm bars may mirror the placement of the storm bars 32 shown in FIG. 2, being positioned directly opposite the shutter from the outside storm bars. Providing storm bars on both sides of the shutter can increase the strength and integrity of the shutter system 30, enabling it to withstand stronger forces.

The storm bars 32 serve to hold a wider shutter 20 in place and prevent it from disengaging from the first and second side rails 14, 16 when it receives a force. For example, if the high winds of a hurricane launch a projectile at the shutter 20, the storm bars 32 can prevent the slats 22 and shutter 20 from bending so much that they slip out of the first and second side rails 14, 16. Thus, in cases where the shutter system 30 covers a glass-enclosed window or door, the storm bars 32 can help prevent the shutter 20 from being damaged, as well as the glass panel behind the shutter 20. In addition, in some embodiments, the thickness of the slats 22 is designed to inhibit flexing transverse to the slat span. For example, embodiments using the 6 millimeter thick polycarbonate slat previously discussed can hinder such flexing.

To facilitate installation, some embodiments of the invention include a shutter kit. In one embodiment, a shutter kit for covering an opening of a building comprises a housing having a torque tube, a shutter having first and second side ends and top and bottom ends. The shutter has a plurality of panels each having a slat comprising a non-opaque polycarbonate material. The shutter is coupled at its top end to the torque tube. The kit further includes first and second side rails that define tracks for receiving the first and second sides of the shutter and a plurality of storm bars for reinforcing the shutter. It will be appreciated that this is just one possible embodied shutter kit and that other embodiments may include additional or fewer components.

FIG. 3 is a top cross-sectional view of the storm bar 32 according to one embodiment. The storm bar 32 takes the form of a rectangular tube with a width W, depth D, and thickness T, although other geometric configurations may also be used as will be described in more detail hereafter. The storm bar 32 can comprise 6063-T6 aluminum alloy or another suitable material, and may be extruded or otherwise suitably manufactured. Depending upon the particular application, the storm bar 32 can be sized to withstand greater or lesser forces depending upon the span of individual storm bars and the spacing of the storm bars 32. For example, in one embodiment, a storm bar having dimensions of about 2″×4″×0.125″ (W×D×T) can withstand a maximum pressure greater than that of a storm bar having dimensions of about 2″×3″×0.125″. Similarly, a storm bar with a greater thickness, such as about 0.25″ can withstand greater pressures than a storm bar with a thickness of about 0.125″.

FIG. 4 is a side cross-sectional view of the shutter system 30 mounted according to one embodiment of the invention. As is shown, the shutter system 30 covers a window 35. It will be appreciated that although this particular embodiment shows a window mounting, other suitable mountings are also contemplated. For example, the shutter system 30 can be mounted to cover a doorway or any other opening. Further, the shutter system can cover lower level or upper level openings, such as second story windows. Various mounting brackets, build-outs, or direct mounting to a concrete slab are also envisioned. In some embodiments, the shutter system 30 is mounted on an exterior surface of a building wall, as shown in FIG. 4. In other embodiments, the shutter system 30 is at least partially mounted on an interior surface of a building wall, thus putting the shutter between any glass panels and building occupants for additional safety, and maintaining a clean appearance of the building from the outside.

It is also contemplated that the shutter system can cover a surface such as a building wall, particularly when the shutter system is used for advertising. As previously mentioned, the shutter system 30 can also be used within a building to cover an opening such as an interior window or doorway, or otherwise. For example, in some embodiments the shutter system 30 is used within an airport to cordon areas of restricted access, and/or to display information such as warnings, instructions, or advertisements, as will be described hereafter.

Referring again to the embodiment of FIG. 4, the shutter system 30 is shown mounted to sections 36 of a poured concrete wall. One or more inside storm bars 38 are mounted at the top end 31 and the bottom end 33 to the sections 36 with angle brackets 40. The angle brackets 40 can be attached to the wall sections 36 with suitable fasteners, such as, for example, tapcon, calk-in, or power-bolt anchors. One or more outside storm bars 32 are mounted at the top end 31 to the header 34 and at the bottom end 33 to a wall section 36 through a number of angle brackets 40.

The shutter system 30 is positioned in front of the window 35, which comprises at least one glass panel 44. According to some embodiments, the system requires a minimum distance dl between the glass panel 44 and the inside storm bar(s) 38, and a minimum distance d2 between the glass panel and the shutter 20. Such a minimum spacing helps ensure that if the shutter 20 and/or the storm bars 38 flex during a storm, they will still not break the glass panel 44. For example, in one embodiment, d I is about 2.0″ or greater and d2 is about 3″ or greater. The inside and outside storm bars 32, 38 have a distance, d3, between them that can be varied according to a particular installation, thus placing the storm bars 32, 38 within varying distances from the shutter 20. In the embodiment shown, d3 is approximately equal to a width of the side rails (not shown), which may be about 2″.

FIGS. 5 and 6 show alternate fastening mechanisms for attaching the storm bars 32, 38 to the angle brackets 40. FIG. 5 illustrates a fixed storm bar mounting wherein the storm bar is fixedly mounted to the angle brackets with two sheet metal screws 46 per side. Such a configuration may be useful in situations where it is desirable to permanently mount the storm bars. FIG. 6 illustrates a removable mounting of the storm bar to the angle brackets 40 according to another embodiment. The storm bar is removably fastened to the angle brackets with two bolts 48 and wing nuts 50. Such a removable configuration can be helpful in situations where it is desirable to remove the storm bars when the shutter system is unneeded. For example, after the threat of a hurricane has passed, shopkeepers may prefer to remove the storm bars from in front of a store window in order to provide an unobstructed and aesthetically appealing view to passersby.

FIGS. 7 a-7 d illustrate various arrangements of shutter systems, some including storm bars. According to some embodiments, the shutter system can be designed to accommodate the exact configuration and dimensions of windows, doors and other openings in a building. Depending upon the width of an opening, different slat 22 spans and storm bar configurations can ensure that the integrity of the shutter system is maintained. With reference to FIG. 7 a, an opening's width may be shorter than a maximum slat span, L, such that storm bars are not needed. For example, a maximum span L is about 6′-4″ for a system that only needs to withstand a maximum load of 35 pounds per square foot (p.s.f.), while a maximum slat span L of about 3′-10″ may be required for a maximum force of 160 p.s.f

As shown in FIGS. 7 b-7 d, depending upon the desired length of slat (i.e., width of shutter), storm bars 32, 38 can be added at intervals not greater than the maximum slat span, L, to reinforce the shutter 20. Referring to FIG. 7 c, the storm bars 32, 38 are mounted not greater than the maximum slat span L away from the first and second side rails 14, 16. Referring to FIGS. 7 b and 7 d, the storm bars 32,38 are mounted between the first and second side rails 14, 16 such that the spacing between consecutive storm bars and side rails is not greater than the maximum slat span L.

Having described embodiments of the shutter system, in one embodiment a method of securely covering an opening in a wall of a building includes providing such a shutter system including a housing, a shutter, and a first and a second side rail. As previously described, the shutter comprises a first side end, a second side end, a top end, a bottom end, and a plurality of panels. The panels each have a slat and at least one of the slats comprises a non-opaque polycarbonate material. The method further includes mounting the housing adjacent a top of the opening and mounting the first and second side rails adjacent sides of the opening to receive the shutter as it rolls up and down. The method also includes mounting at least one storm bar adjacent the shutter between the first and second side rails and extending from the top end of the shutter to the bottom end of the shutter for reinforcement.

FIGS. 8 and 9 illustrate another aspect of the shutter 20 according to some embodiments. While panels with non-opaque slats can advantageously provide for light transmission into and out of a building, the hinge assemblies 51 connecting adjacent slats 22 can decrease the available viewing area of the shutter 20. For example, each hinge assembly 51 includes a top hinge member 52 and a bottom hinge member 53 as previously described, which in many cases are manufactured from an aluminium alloy. A shutter 20 with a viewing area frequently interrupted by the hinge assemblies can be aesthetically unappealing and hinder the ability of, for example, customers to view into a store window.

In order to maximize the area of the shutter 20 taken up by the slats 22 and minimize the area taken up by the top and bottom hinge members 52, 53, the height of the slats 22 can be varied to provide a square roll-up feature. Referring to FIGS. 8 and 9, one embodiment is depicted in which the slats 22 increase in height, h, from the top 19 of the shutter to the bottom 21 of the shutter. For example, in a shutter having 20 slats, a top slat 54 can have a height, h, of about 5.12″ while a base slat 56 can have a height, h, of about 9.40″. The progressively increasing size of the slats 22 allows the panels 58 to wrap around the torque tube 60 in a square like fashion, each panel 58 directly overlapping another panel 58. As shown in FIG. 8, straps 61 and a storage bumper 62 can be included in some embodiments to further align the panels 58 as they begin to roll up. Because each winding around the torque tube 60 only requires four hinges 51, a greater area is available for the viewing slats than for a configuration requiring a greater number of hinges 51 to wind up in a more cylindrical fashion.

As previously discussed, displaying information and advertisements in windows, doors, and other openings may be desirable features, especially for shopkeepers. While non-opaque, such as transparent, slats can allow viewing through a shutter, it can be desirable to present information more directly to people viewing the shutter. For example, in the presence of severe weather, shopkeepers may wish to display weather related information, such as weather warnings, emergency information, or modified store hours. In other cases, it can be advantageous to present advertisements to passersby when the shop is closed due to weather related activity or otherwise. Or, as previously described, managers of larger facilities, such as airports, may wish to use a shutter system with a projection system.

In order to address these and other desires, some embodiments of the invention provide shutter systems employing projections panels and a projection system among other components. FIG. 10 illustrates a shutter system 70 combined with a projection system 74 according to some embodiments of the invention. The shutter system generally includes a shutter 71 with a plurality of projection panels 72. As in other embodiments, the projection panels 72 also operate to securely close off an opening (e.g., a window or doorway), thus providing a secure building. In one embodiment, Storm bars are included to strengthen the shutter, but may be removed when not needed to provide an unobstructed view. In other embodiments, storm bars are not used.

The projection panels 72 each have a slat and top and bottom hinge members similar to embodiments previously described. In some embodiments, however, the slat comprises a nontransparent.( e.g. milky white) polycarbonate material having diffusion properties capable of transferring a display image projected at one side such that is can be seen when viewing the material from the opposite side. For example, in one embodiment the polycarbonate allows as little as 4% light transmission with a diffusion factor of about 0.8. Thus, customers and passersby can see the display image from outside the building when it is projected from inside the building.

The polycarbonate material is solidly constructed and provides an adequate level of protection from severe weather and theft deterrent as it encloses the building windows, doors, and other openings. For example, in one embodiment, the polycarbonate material has strength characteristics similar to the Lexan polycarbonate, type 9030 already discussed. While one possible material for the projection panels 72 has been described, it will be appreciated by those skilled in the art that other materials having similar properties may also be employed.

The projection system 74 typically includes a projector 76 coupled to a computer (PC) 78 or similar controller. For example, the projector 76 can be attached using a VGA cable or a CA T5 network cable to the PC 78. The PC/controller 78 includes necessary software to implement the graphic display as desired. As further described below, the projection system 74 is specifically configured to cooperate with the projection panels 72 to provide an effective and usable display of information. In addition, an in-store display 80 can be coupled to the PC 78 for in-store narrow casting or displaying information identical to that displayed on the projection panels 72.

Further details regarding one potential connection methodology are shown in FIG. 11. As can be seen, projection system 74 includes PC 78 connected via various connections to projector 76 and a display unit 80. More specifically, PC 78 is connected to a VGA splitter 82, which can then provide signals to both projector 76 and display 80. Optionally, certain components may also be added including a network switch 84 and optional image input devices 86, such as cameras. Each of these components are connected via appropriate connection methodology such as CAT5 network cables, VGA cables, USB cables, UTP or fire wire cables etc. As will be easily recognized by those skilled in the art, appropriate connections and connection methodologies provide certain advantages in the right situations. For example, a wireless connection methodology may be advantageous in certain situations.

In place of VGA other cables like VGA, DVI, HDMA may be used.

Based upon the configurations above, it can be seen how various information can easily be displayed on both the in-store display 80 and the projection panels 72 of the shutter 71. Changes and modifications to the information displayed can be easily achieved via the PC 78 making up the system. In addition, it should be noted that this PC 78 could also potentially control the display of information on multiple shutter systems in various locations. FIG. 12 provides one illustration of an implementation where multiple shutter systems are used. As shown, appropriate network connections are provided so that image data on a content server 88 is accessible by multiple PCs 78 at each of the multiple locations. More specifically, a first location 90, a second location 92, a third location 94, and a fourth location 96 are all illustrated in FIG. 12. Each of these locations can include the components outlined above and shown in FIG. 11. In addition, each location includes a network router 98 connected to content server 88 through a network 100, e.g., through an Internet connection.

FIG. 12 also illustrates a content server side fire wall 102, and related location fire walls 104 for providing desired levels of information security. In this particular application, all locations could easily be programmed to display identical information if appropriate. Alternatively, the actual controlling PC at each particular location could run slightly different display presentations, all based upon image data contained on content server 88. Additionally, FIG. 12 illustrates the possibility of modifying content from remote locations via appropriate control of the content server. For example, the image content can be changed from a stand-alone PC connected to the content server 88 through the network 100 or through several other interfaces (e.g., webpage 110 database, E-mail 112, SMS 114, etc.) in a networked environment.

As previously discussed, the shutter system 70 used for displaying information includes any number of projection panels 72. In order to effectively display information, desired image data can be loaded into an image template. The image template corresponds to the shutter 71 design, including, for example, multiple image locations corresponding to the non-transparent slats, and image gaps corresponding to areas taken up by hinges or other opaque areas within the shutter 71. For example, the image locations may increase in height from the top slat to the bottom slat corresponding to the slat design of the embodiment shown in FIGS. 8 and 9. In addition, the image locations may take into account the placement of storm bars with the shutter system, providing image gaps in locations where the view is obstructed by the storm bars.

Once the PC/controller loads the desired image data into the template, the projection system 74 projects the loaded image upon the one or more shutters 71. Thus images containing advertisements or any other information (e.g., time, date, weather info, travel info, stock info, sports info, etc) can be displayed to shoppers or those passing by the store. It will be easily recognizable that a wide variety of image templates are possible according to different shutter designs. As just one example, projection panels 72 may only comprise a specific section of the shutter 71, with non-opaque viewing panels occupying other sections. A corresponding image template can ensure that the image is projected only onto the section of the shutter comprising the projection panels.

As previously described, each hinge assembly 51 includes a top hinge member 52 and a bottom hinge member 53 that will now be described in further detail. FIGS. 13 and 14 are side cross-sectional views of the top hinge member 52 and the bottom hinge member 53, respectively, according to some embodiments. FIG. 15 is a side cross-sectional view of the slat 22 according to some embodiments. Although not shown in these cross-sectional views, it is contemplated that in some embodiments the top and bottom hinge members 52, 53 extend the length of the slat 22. Such a configuration can add increased strength to individual panels in order to support the greater weight of longer slats, or in order to withstand greater forces such as from severe weather.

Referring to the embodiment in FIG. 13, the top hinge member 52 includes a top hook 120 that couples with the bottom hinge member 53 of another panel. The top hinge member 52 also includes and a top slat holder 122 that fastens the top hinge member 52 to a top 124 of the slat 22. As can be seen in FIG. 15, the top 124 of the slat 22 includes a groove 126, while the top slat holder 122 includes a protrusion 128 sized to fit within the groove 124 in order to hold the slat 22 more securely within the top slat holder 122. Referring to FIG. 14, in the embodiment depicted, the bottom hinge member 53 includes a bottom hook 130 that couples with the top hook 120 of the top hinge member 52. This coupling allows rotation between shutter panels so that the shutter can wrap around and unwind from the torque tube as it is respectively raised and lowered. The bottom hinge member 53 also includes a bottom slat holder 132. The slat holder 132 includes a protrusion 134 sized to fit within a groove 136 in a bottom 138 of the slat 22. Thus, the slat 22 is held more securely within the bottom slat holder 132. While one embodiment of the hinge assembly 51 has been described herein, this description is not meant to limit the scope of the disclosure.

FIGS. 16, 17, and 18 are various cross-sections of storm bars according to different embodiments. While the storm bars can have rectangular cross-sections, such as in the embodiments in FIGS. 2-7, the storm bars are not limited to rectangular or square configurations. FIG. 16 illustrates a first storm bar 140 with a triangular cross-section, FIG. 17 illustrates a second storm bar 142 with an oval cross-section, and FIG. 18 illustrates a third storm bar 144 with a circular cross-section. In addition, in other embodiments the storm bars may have any other suitable cross-sections, or a combination of variously shaped storm bars may be used on the same shutter system.

FIGS. 19 and 20 illustrate various configurations of storm bars 150 coupled together with one or more support bars 152 according to some embodiments. The support bars 152 can provide additional strength to the shutter system, while also allowing an easier installation of multiple storm bars 150. For example, with reference to FIG. 19, support bars 152 extend horizontally across the tops and bottoms of the storm bars 150, which allows all of the storm bars 150 to be installed simultaneously. FIG. 20 illustrates an alternate configuration with only one support bar 152.

Thus, embodiments of the ENHANCED PROTECTION AND SECURITY SHUTTER SYSTEM are disclosed. Although embodiments of the invention have been described in considerable detail, other embodiments of the invention are possible. While exemplary embodiments of this invention have been illustrated and described, one skilled in the art will appreciate that various changes, adaptations, and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. 

1. A shutter system for covering an opening in a wall of a building comprising: a housing, said housing comprising a torque tube; a shutter, wherein the shutter includes a first side end, a second side end, a top end, a bottom end, and a plurality of panels wherein each of the panels is comprising a slat wherein at least one of the slats comprises a non-opaque polycarbonate material. wherein the shutter system comprises at least one storm bar for reinforcing the shutter.
 2. The shutter system according to claim 1 further comprising first and second side rails that define tracks for receiving the first and second side ends of the shutter.
 3. The shutter system according to claim 2 wherein a first storm bar is mounted adjacent to the shutter between the first and second side rails and is extending from top end of the shutter to the bottom end of the shutter for reinforcement.
 4. The shutter system according to claim 3 wherein the first storm bar is mounted not greater than a maximum slat span away from the first side rail and the second side rail.
 5. The shutter system according to claim 1 comprising storm bars on both sides of the shutter to increase the strength and integrity of the shutter system, enabling it to withstand stronger forces.
 6. The shutter system according to claim 5, wherein the first storm bar is mounted adjacent an outside surface of the shutter.
 7. The shutter system according to claim 6 further comprising a second storm bar mounted adjacent an inside surface of the shutter, directly opposite the shutter from the first storm bar.
 8. The shutter system according to claim 7 wherein the first and second storm bars comprise an aluminium alloy.
 9. The shutter system according to claim 8 wherein the first and second storm bars comprise rectangular tubes.
 10. The shutter system according to claim 1, further comprising at least a second storm bar mounted adjacent to the shutter between the first and second side rails and extending from the top end of the shutter to the bottom end of the shutter.
 11. The shutter system according to claim 10, wherein the first and at least second storm bars are mounted adjacent an outside surface of the shutter.
 12. The shutter system according to claim 11 further comprising at least third and fourth storm bars mounted adjacent an inside surface of the shutter, directly opposite the shutter from the first and second storm bars, respectively.
 13. The shutter system according to claim 1 wherein each of the panels comprises a slat and a top hinge member and a bottom hinge member.
 14. The shutter system according to claim 13, wherein each slat is at least 6 millimeter thick.
 15. The shutter system according to claim 14 wherein the slats comprise a polycarbonate material to provide enough strength to the system.
 16. The shutter system according to claim 15 wherein at least one of the slats is non-opaque, providing various amounts of light transmission and transparency.
 17. The shutter system according to any of the preceding claims wherein the top and bottom hinge members of adjacent slats connect to form hinge assemblies that reinforce the slats and strengthen the shutter against breaking.
 18. The shutter system according to claim 17 wherein the shutter hinges, side rails, and other components comprise 6063-T6 aluminum alloy or other suitable material.
 19. The shutter system according to claim 18 wherein the housing and torque tube comprise galvanized steel, among other suitable materials.
 20. The shutter system according to claim 1, wherein the shutter system is at least partially mounted on an exterior surface of the wall.
 21. The shutter system according to claim 1, wherein the shutter system is at least partially mounted on an interior of the wall.
 22. The shutter system according to claim 1, wherein the slats increase in height from the top end of the shutter to the bottom end of the shutter.
 23. The shutter system according to claim 22, wherein the slats wrap round the torque tube in a square like configuration.
 24. The shutter system according to claim 1 wherein the shutter rolls up and down within the tracks defined by the first and second side rails by way of the torque tube and/or one or more motors or other drive assemblies.
 25. The shutter system according to claims 1 to 12 wherein at least one of the storm bars in the shutter system are optionally removably mounted.
 26. The shutter system according to claim 1 wherein the shutter covers an opening in a wall in such as a window or door, in a building such as a store, hotel, or house.
 27. A method of securely covering an opening in a wall of a building, comprising: providing a shutter system comprising a housing, a shutter, and a first and a second side rail, wherein the shutter comprises a first side end, a second side end, a top end, a bottom end, and a plurality of panels wherein each of the panel is comprising a slat, wherein at least one of the slats comprises a non-opaque polycarbonate material; mounting the housing adjacent a top of the opening; mounting the first and second side rails adjacent sides of the opening to receive the shutter as it rolls up and down; and mounting at least one storm bar adjacent the shutter between the first and second side rails and extending from the top end of the shutter to the bottom end of the shutter for reinforcement
 28. The shutter system according to claim 1 wherein the shutter system covers a surface such as a building wall and is used to display information such as warnings, instructions, or advertisements
 29. The shutter system according to claim 28 wherein the shutter system allows for displaying information and advertisements in windows, doors, and other openings.
 30. The shutter system according to claim 29 further comprising a projection panel and a projection system wherein the slat comprises a nontransparent, polycarbonate material having diffusion properties capable of transferring a display image projected at one side such that it can be seen when viewing the material from the opposing side.
 31. The shutter system according to claim 30 wherein the projection system comprises a projector coupled to a controller such as a computer.
 32. The shutter system according to claim 31 wherein the projection system is configured to cooperate with the projection panels to provide an effective and usable display of information.
 33. A shutter kit for covering an opening of a building, comprising: a housing comprising a torque tube; a shutter comprising a first side, a second side, a top end, a bottom end, and a plurality of panels each comprising a slat, the shutter coupled at the top end to the torque tube, and wherein at least one of the slats comprises a non-opaque polycarbonate material for transmitting light through the shutter; first and second side rails defining tracks for receiving the first and second sides of the shutter, respectively; and a plurality of storm bars for reinforcing the shutter. 